Mesh made of a composite material

ABSTRACT

A mesh ( 12 ) is made of a composite material having fibers. The fibers are mutually arranged to form a weft ( 14 ) and a warp ( 16 ). The weft ( 14 ) includes at least one weft yarn ( 142 ) which has at least one fiber. The warp ( 16 ) includes at least one warp yarn ( 162 ) which has at least one fiber. In the mesh made of a composite material ( 12 ), the weft ( 14 ) and the warp ( 16 ) are mutually connected at intersection points ( 18 ) by interlacing ( 20 ).

FIELD OF APPLICATION

The present invention relates to a mesh made of a composite material. In particular, the present invention relates to connection elements made of a composite material to be used, e.g., for consolidating, protecting, or securing structures in the construction and industry field and the infrastructure and road sector.

BACKGROUND ART

It is known that there are many techniques for consolidating architectural structures or securing them or more in general for strengthening or reinforcing infrastructures and road pavements. In particular, there are techniques which use rigid meshes made of a composite material made with fibers embedded in a thermosetting resin. The yarns thus composed are woven together to form the mesh, twisting the resin-impregnated transverse fibers to the longitudinal ones.

The meshes made of a composite material are made starting from fibers (e.g., glass, carbon, aramid, basalt, and/or PBO) embedded in a thermosetting or possibly thermoplastic resin.

In some applications, the meshes are embedded in a mortar with binding agents, which may be of different types, and are used for consolidating existing structures (masonry, concrete, reinforced concrete, etc.) creating a reinforced plaster to be applied onto the surfaces, or as slabs for manufacturing load-bearing floors.

The mesh, for example, may be blocked in position by using junction or connection elements inserted in holes made in the substrate to be consolidated/reinforced. The junction elements are generally made of metal or another material and are typically L-shaped, in which the two sides are substantially perpendicular to each other. In use, once an anchoring resin has been distributed inside the hole, one side is inserted into the hole obtained in the masonry, while the other side is arranged parallel to the surface of the masonry. The mesh and junction elements are therefore embedded inside a mortar with binding agents which may be of different types.

If the mesh is positioned on both surfaces of the masonry, it is possible to block it in position, making a through-hole so that the two meshes may be connected to each other with two junction elements: a first junction element inserted at one surface, and a second junction element inserted at the opposite surface.

In other applications, the mesh made of a composite material is inserted into a bituminous road surface to reduce the long-term effects of vehicle traffic or to extend the service life of the operation.

Furthermore, in further applications, this type of mesh made of a composite material is used to create exposed fencing using structures, such as posts and bracing.

For example, document EP 3431666A1 describes a process for making a mesh made of a composite material which can be made from fibers totally embedded in resin.

Meshes of this type are also described in KR 102 102 435 B1 and U.S. Pat. No. 5,244,693 A.

The prior art, although widely appreciated, is not without drawbacks.

First of all, if it is necessary to reinforce a wall with changes of surfaces, e.g., in the case of intersections between masonry walls, intersections between ceilings, and masonry walls, it is necessary to prepare two separate meshes on the two walls and join them together, overlapping each mesh with a preformed element made in the factory to avoid creating discontinuities between reinforcement elements.

Indeed, being rigid, each mesh does not allow the mesh itself to be placed straddling two surfaces which are not consecutive and parallel. In other words, it is not possible to turn the mesh over on changes of surface.

The same problem occurs in the case of meshes used as fencing.

Furthermore, if the mesh is used to reinforce horizontal or sub-horizontal surfaces (e.g., road screeds), it is difficult to keep it in position during the screed or bituminous conglomerate laying operations. Today the problem is solved by nailing or, alternatively, by creating piles made of the same material as the screed on top of the mesh, which prevent the mesh from lifting.

PRESENTATION OF THE INVENTION

Therefore, the need is felt to solve the drawbacks and limitations mentioned above with reference to the prior art.

Firstly, the need is felt for a mesh made of composite material adapted to reinforce a wall with changes of surfaces, e.g., in the case of intersections between masonry walls.

Furthermore, the need is felt for a mesh that can be turned around easily and quickly to follow a change of surface, without having a drastic drop in performance at the portion subject to folding.

The need is also felt for a mesh made of a composite material which can be used to reinforce horizontal or sub-horizontal surfaces without the difficulty of keeping it in position during screed-laying operations.

Such needs are at least partially fulfilled by a mesh made of a composite material according to claim 1.

DESCRIPTION OF THE DRAWINGS

Further features and advantages of the present invention will be more comprehensible from the following description of preferred embodiments given by way of non-limiting examples, in which:

FIG. 1 diagrammatically shows a perspective view of a first embodiment of a mesh made of a composite material according to the present invention;

FIG. 2 diagrammatically shows a perspective view of an alternative embodiment of a mesh made of a composite material according to the present invention;

FIGS. 3 and 4 diagrammatically show two views of a component of a mesh made of a composite material according to the present invention;

FIG. 5 diagrammatically shows a view of a component of a mesh made of a composite material according to the present invention; and

FIG. 6 diagrammatically shows a perspective view of a further alternative embodiment of the present invention.

Elements or parts in common to the embodiments described will be indicated hereafter using the same reference numerals.

DETAILED DESCRIPTION

FIG. 1 diagrammatically shows a component of a mesh made of a composite material according to the present invention indicated by reference numeral 12.

The mesh made of a composite material 12 comprises fibers mutually arranged to form a weft 14 and a warp 16. According to a possible embodiment, weft 14 and warp 16 are substantially perpendicular to each other. In alternative embodiments, weft 14 and warp 16 may be arranged at mutually different angles, e.g., 45°.

According to a possible embodiment, the mesh made of a composite material may comprise two warps 16, 216. In this case, the intersection points 18 may comprise one weft yarn and two warp yarns. Advantageously, the warp yarns 16, 162 may have substantially perpendicular mutual directions. Furthermore, in a possible embodiment, the weft yarns may be arranged at about 45° to the warp yarns.

The weft 14 comprises at least one weft yarn 142, which comprises at least one fiber. The warp 16 comprises at least one warp yarn 162, which comprises at least one fiber.

The weft 14 and the warp 16 are mutually connected at intersection points 18 by interlacing means 20.

According to a possible embodiment, the mesh made of a composite material 12 may comprise a binder. The weft 14 and/or the warp 16 are impregnated with said binding agent in predetermined impregnation zones so that some portions of weft yarns 142 and/or some portions of warp yarns 162 consist of portions of virgin fibers.

According to a possible embodiment, the predetermined impregnation zones comprise intersection points 18 between weft 14 and warp 16 and thus act as interlacing means 20.

According to a possible embodiment, the warp yarns 162 may be impregnated with the binder only at intersections 18 with the weft yarns 142. In this case, the predefined impregnation zones comprise the entirety of the weft yarns 142 or only a small circumference of weft yarns 142 at the intersections between the weft yarns 142 and the warp yarns 162.

According to possible alternative embodiments, the interlacing means 20 between the weft 14 and the warp 16 may comprise mechanical type junction elements, polymeric material elements, or bonding through an adhesive. In particular, the mechanical type interlacing means may be, for example, banding made of metallic material.

For example, an example of banding made of metallic material, obtained by means of a tie, is diagrammatically shown in FIG. 5 .

On the other hand, the interlacing means 20 of polymeric type may be, for example, banding made of polymeric material, obtained with a tie similar to the one shown in FIG. 5 , but made of polymeric material.

FIGS. 3 and 4 show a further embodiment of the interlacing means 20 made in the form of a button. In this case, the interlacing means 20 may comprise two components: a first component 202 provided with pins 206 (e.g., two), and a second component 204 provided with respective seats 208. The coupling between first component 202 and second component 204 may be achieved by coupling between pins 206 and respective seats 208. Advantageously, such a coupling may be non-reversible.

Again in this case, the first and second components can be made of metal or polymeric material.

In this discussion, the expression virgin fibers is understood to mean fibers which were not been embedded in the binder at a portion thereof. In technical jargon, virgin fibers can also be referred to as “dry” fibers.

The fibers may comprise synthetic organic fibers, natural organic fibers, inorganic fibers, and/or even metallic fibers.

Synthetic organic fibers may comprise, for example, aramid fibers, polyester, and/or even polyparaphenylene benzobisoxazole (PBO).

Natural organic fibers may comprise, for example: cotton, hemp, flax, sisal, bamboo, wood, wool, silk, etc.

The inorganic fibers may comprise, for example: glass, carbon, basalt, quartz, etc.

The metallic fibers may comprise, for example: stainless steel, carbon steel, copper, brass, aluminum, titanium, etc.

According to a possible embodiment of the present invention, each weft yarn 142 and/or even each warp yarn 162 may comprise fibers of a mutually different type. In other words, the mesh made of a composite material can be made by combining various types of fiber, even with different percentages in weft 14 and warp 16.

According to a possible embodiment, the interconnecting means 20 may be a tie, e.g., of a fibrous type in winding and/or metallic type in the same manner.

According to a possible embodiment, the binder (also called a matrix) may be a resin.

The resin can be either of the thermosetting or the thermoplastic type.

In the case of thermosetting resin, this may, for example, be of the vinyl-ester, polyester, bisphenol, acrylic type, etc.

In the case of thermoplastic resins, the resin may be selected from the group comprising PVA, PP, Pen, etc.

According to a possible embodiment, the resin may contain catalysts for the polymerization/crosslinking process. The catalysts may be such that they are activated e.g., by heat, radiation, infrared or UV radiation.

Advantageously, the fibers may be treated with surface additives to improve their durability and/or adhesion with the resin and/or other organic/inorganic and other matrices, such as asphalt, both before and after the application of the interlacing means 20.

According to a possible embodiment of the present invention, the weft yarns 142 may comprise a plurality of fibers, e.g., glass and steel fibers.

According to a possible embodiment of the present invention, the warp yarns 162 may comprise two fiber bundles 164, 166 of balanced (same amount of fiber) or, alternatively, unbalanced content.

According to alternative embodiments, the warp yarns 162 may comprise a plurality of fibers, e.g., glass and steel fibers.

According to alternative embodiments, the weft 14 may be made from preformed bars or bars resulting from a pultrusion process.

As shown in FIG. 1 , according to a possible embodiment, the weft yarns 142 or warp yarns 162 may be impregnated with said binder and preformed. For example, the weft yarn 142 or warp yarn 162 may be substantially flat, or circular, or otherwise shaped (e.g., trapezoidal).

Again with reference to FIG. 1 , the warp yarns 162 may be made by fibers 164, 166 twisted about an axis of the warp yarn 162 itself.

Thus, with reference to the embodiment shown in FIG. 1 , since the warp yarns between one intersection 18 and the other are not impregnated with resin, the mesh made of a composite material can be easily bent in directions substantially parallel to the weft yarns 142. In alternative embodiments, the weft yarns between one intersection 18 and the other are not impregnated with resin, the mesh made of a composite material can be easily bent in directions substantially parallel to the warp yarns 162.

According to alternative embodiments, the predetermined impregnation zones may also refer, for example, to a plurality of warp yarn portions 162 between one intersection 18 and another, leaving virgin fiber portions on the warp yarns 142 between two consecutive weft yarns 142.

According to possible embodiments, the impregnation can take place in spots (drip), with a continuous process and/or by molding.

The advantages which can be achieved by a mesh made of a composite material according to the present invention are therefore apparent.

Firstly, a mesh made of a composite material adapted to reinforce a wall with changes of surfaces, e.g., in the case of intersections between masonry walls, is made available.

Furthermore, a mesh which would allow it to be turned back to follow a change of surface is made available.

Again, the mesh made of a composite material according to the present invention can be used to reinforce horizontal or sub-horizontal surfaces without the difficulty of keeping it in position during the screed or the bituminous conglomerate laying operations.

Furthermore, when the predetermined impregnation zones are made near and on the intersection of weft 14 and warp 16, keeping only the nodal zone of the rigid mesh, it is possible to fold and arrange the mesh 12 in a three-dimensional manner, thus adapting it, for example, to a spherical truncated element (e.g., the surface of a dome).

In particular, the predetermined impregnation zones can be arranged according to specific requirements, e.g., such as the need to bend the mesh in several directions, even at a mutual angle. Advantageously, the impregnation zones are such as to leave portions of weft yarns 142 and/or portions of warp yarns 162 made of virgin fibers, which can thus allow the mesh to be bent in inclined directions relative to the direction of the respective portions of weft yarns 142 and/or portions of warp yarns 162.

For example, the predetermined impregnation zones may comprise parallel and consecutive portions of weft yarns 142 and/or parallel and consecutive portions of warp yarns 162.

According to a possible embodiment, a mesh may comprise mutually different weft yarns 142 and/or even mutually different warp yarns 16. For example, a weft 14 and/or even a warp may be made from yarns that have mutually different fibers.

According to a possible embodiment, in a mesh at least part of the weft yarns 142 can be made from fibers of different materials to make mesh zones with predetermined technical characteristics, and/or in a mesh at least part of the warp yarns 162 can be made from fibers of different materials to make zones of the mesh with predetermined technical characteristics.

In the embodiments described above, a person skilled in the art will be able to make changes and or substitutions of elements described with equivalent elements without departing from the scope of the appended claims to satisfy specific requirements.

For example, the mesh made of a composite material may be used in conjunction with coatings, laminates, fabrics, non-woven fabrics, coupling films by means of the intersection points 18 or dry fibers. Again, mechanical or polymeric connection means may be adapted to connect with corresponding elements for joining with a matched element. 

1-13. (canceled)
 14. A mesh made of a composite material comprising fibers; said fibers being mutually arranged to form a weft and a warp; said weft comprising at least one weft yarn comprising at least one fiber; said warp comprising at least one warp yarn comprising at least one fiber; wherein said weft and said warp are mutually connected at intersection points by interlacing, and wherein said mesh further comprises a binding agent, said weft and/or said warp being impregnated with said binding agent in predetermined impregnation zones so that some portions of weft yarns and/or some portions of warp yarns comprise portions of virgin fibers.
 15. The mesh of claim 14, wherein said predetermined impregnation zones comprise the intersection points and act as interlacing.
 16. The mesh of claim 14, wherein said weft and said warp have a direction substantially perpendicular to each other.
 17. The mesh of claim 14, wherein said weft and said warp have directions mutually inclined by an angle smaller than 90°.
 18. The mesh of claim 14, wherein said fibers comprise synthetic organic fibers, natural organic fibers, inorganic fibers, and/or metallic fibers.
 19. The mesh of claim 18, wherein said synthetic organic fibers are aramid, polyester and/or polyparaphenylene benzobisoxazole (PBO) fibers; said natural organic fibers are cotton, hemp, linen, sisal, bamboo, wood, wool, and/or silk; said inorganic fibers are glass, carbon, basalt, and/or quartz; said metallic fibers are stainless steel, carbon steel, copper, brass, aluminum, and/or titanium.
 20. The mesh of claim 14, wherein said binding agent is a thermosetting or thermoplastic resin.
 21. The mesh of claim 20, wherein said thermosetting resin is selected from the group consisting of resins of the vinyl-ester, polyester, bisphenolic and acrylic resins and the thermoplastic resin is selected from the group consisting of type PVA, PP, Pen resins.
 22. The mesh of claim 14, wherein the weft yarns are impregnated with said binding agent and preformed.
 23. The mesh of claim 14, wherein the warp yarns comprise fibers twisted about an axis of the warp yarn.
 24. The mesh of claim 14, wherein the warp yarns are impregnated with the binding agent at intersections with the weft yarns, and the warp yarns comprise virgin fibers between one intersection and the other.
 25. The mesh of claim 14, wherein said predetermined impregnation zones are configured to leave portions of weft yarns and/or portions of warp yarns made of virgin fibers, which allow the mesh to be bent in inclined directions relative to a direction of respective portions of weft yarns and/or portions of warp yarns.
 26. The mesh of claim 14, wherein at least part of the weft yarns comprise fibers of different materials to make mesh zones with predetermined technical characteristics, and/or in a mesh wherein at least part of the warp yarns comprise fibers of different materials to make zones of the mesh with predetermined technical characteristics. 